Optical monitoring of welding systems



OPTICAL MONITORNG OF WELDING SYSTEMS I; 50a/wf@ l 3 Sheets-Sheet Filed Aug. 2 1968 F. RESINS @I ISI@ OPTICAL MONITORING OF WELDING SYSTEMS 3 sheeIS-SheeI-z Filed Aug. 2, 1968 N 5 v 563W" L my@ F. @www OPTICAL MONITORING OF WELDING SYSTEMS 3 Sheets-Sheet f5 Filevd Aug. 2, 1968 j GPTCAL r/IGNIVIORENG 0F WELEEING SYSTEMS U5. Cl. 219-131 I5 Claims ABSTRACT F THE DISCLUSURE A welding system in which a visual image of the weld is transmitted by a flexible fiber optics bundle to a rei motely located detector. A. rotating mask having adjust- Iable apertures periodically interrupts the image at a frequency such that the image appears substantially stat tionary at the detector. The image may be evaluated by visual observation, or it may be scanned to produce an I electrical feedback signal which is effective to control an automatic welding circuit in accordance `with the parameters of the weld being formed.

-mmma-a-k This invention relates to welding systems and more particularly to such systems of the type in which a visual image of the weld is transmitted to a remotely located detector.

The present invention, while of general application, is particularly applicable to welding systems of the type in which electrical current pulses are applied to a welding electrode to generate successive electric arcs for forming droplets of weld material. In order to effectively evaluate the quality of the weld as it is formed, it is highly desirable to ascertain the size of the droplets, the characteristics of the arc and other weld parameters. At pulse frequencies above about twelve pulses per second, however, direct visual observation of the droplets becomes problematic. Accordingly, attempts have been made to evaluate the droplets through the use of high-speed motion pictures, for example. These attempts have not been entirely satisfactory, among other reasons because of the shortness of the actual welding time and the need for shipping and processing the tilm before a meaningful evaluation can be made.

One general object of this invention, therefore, is to provide a new and improved Iwelding system in which a visual image of the weld may be continuously observed as the weld is being formed.

More specifically, it is an object'of this invention to provide a welding system of the character indicated in which the visual image of the weld is modified to produce a substantially stationary representation of the individual droplets of weld material at a remote location.

Another object of the invention is to provide such a welding system in which the intensity of the detected image may be readily adjusted during the welding operation to produce an extremely well-defined representation of thc weld. i

Still another object of this invention is to provide a system for producing a visual image of a weld which is substantially unaffected by splatter or other contaminants.

A further object of this invention is to provide an automatic welding system in which the formation of the weld is continuously controlled in accordance with such parameters as arc shape, size, color, intensity and other phenomena.

A still further object of the invention is to provide novel monitoring apparatus for awelding system which is economical to manufacture and thoroughly reliable in operation.

In one illustrative embodiment of this invention, the welding system includes an electrical circuit for applying l ii current pulses to a welding electrode at a predetermined frequency to generate successive arcs for forming droplets of weld material. A flexible fiber optics bundle or other light conducting means is positioned with one end adjacent the weld and the opposite end at a remote location. The bundle is effective to transmit an optical image of the weld to a detector at the remote location. The image may be evaluated visually at the detector, or it may be scanned to produce an electrical feedback signal for controlling an automatic Welding circuit in response to the weld being formed.

In accordance with one feature of the invention, there is provided unique means for modifying the image transmitted by the light conducting means to produce a substantially stationary representation of the weld at the detector. With this arrangement, the various weld parameters, such as the characteristics of the are, the size of the droplets, etc., may be readily measured during the formation of the weld.

'in accordance with another feature of the invention, in certain particularly advantageous embodiments, the modifying means comprises a rotating mask or reticle which is interposed in the path of the image and is provided with a pair of apertured discs in xed but adjustable relationship with each other. The arrangement is such that the width of the effective aperture of the mask may be quickly and easily varied during the operation of the apparatus to adjust the intensity of the light reaching the detector.

In accordance with another feature of the invention, in some arrangements, there is provided a continuously rotating transparent member between the objective end of the light conducting means and the welding arc. The transparent member is driven by jets of inert gas and is effective to shield the objective end from the deleterious effects of weld splatter and other contaminants.

The present invention, as well as further objects and features thereof, will be understood more clearly and fully from the following description of a preferred embodiment, when read with reference to the accompanying drawings, in which:

FIG. 1 is a schematic representation of an automatic welding system in accordance with one illustrative embodiment of the invention;

FIG. 2 is an enlarged fragmentary sectional View taken along the line 2-2 in FIG. l;

FIG. 3 is an enlarged fragmentary sectional view taken along the line 3 3 in FIG. 1;

FIG. 4 is an enlarged elevational View, with certain parts shown broken away and in section, of a portion of f the system illustrated in FIG. l;

a welding system for producing a seam weld It) between two plates 11 and 12 which form a work piece. The system includes a welding electrode 13 which illustratively is of the consumable type and is supported by a movable arm 14 in juxtaposition to the weld l0. An automatic welding control circuit l5 of conventional construction is electrically connected to the electrode i3 by a conductor I7 and to the plate 12 by a conductor i3. As will be understood, the circuit 15 is effective to apply electrical current pulses to the electrode 13 at a predetermined frequency to generate successive electric arcs between the electrode and the work piece. Each of the generated arcs form a droplet of weld material which passes from the electrode to the weld. The arm 14 moves the electrode I3 along the seam a uniform rate to produce a continuous joint between the plates Il and l2.

in welding systems of the foregoing type, it is highly desirable to determine the various parameters ol the weld during the Ielding operation. The detection of such phenomena as the shape and size of the individual droplets, the arc shape, size, color, intensity, etc., enables the accurate and precise control over the welding circuit to insure the formation of; a uniform and Continous weld.

ln the system of llG. l, the parameters of the weld are readily ascertained through the use Q tfna flexible li' wh" W bundle indicated e1 ally at T ilievlijectire nd El otitho'""Ju'ndle'2U1s tis sdiii'spaced juxtaposition with the electric arc between the electrode i3 and the worl; piece, while the opposite end of the bundle is remotely located with respect to the arc. The bundle is of conventional construction and comprises a multiplicity of fine glass fibers extending from one end of the bundle to the other. The ends of the fibers adjacent the objective end are oriented with respect to the libers at the remote end such that an accurate and well-defined image ot the arc and the droplets being transierred is reproduced at the remote end.

The objective end 2i. of tne bundle 2t) is supported by :t rod 35 which is mounted on a second rod 26. This latter rod is connected by an adjustable bracket 23 to a depending arm 29. The arm 2, is atixed to the electrode support arm E/i by a laterally extending bar 30. The end ill ol the be" l e is thus maintained in iixed relationship with the we electrode i3, such that the movement o the electrode along the seam similarly moves the end best shown in FlG. 4, a transparent dise 35 is rotatably mounted at the end ol` the arm ,Tit-r adjacent the weld it). rl'l e disc 3S is held in place by a stationary cap 36 on the arm'ZG and is positioned such that its outer portion is interposed between the objective end 2i of the bundle 29 and the weld itl. Supported on the arm 26 at the side of the disc 35 opposite that adjacent the cap 36 is a housing 3S. This housing is supplied with an inert gas under pressure through an inlet 39. The central portion ot the disc 35 includes apertures 4t) which are angularly disposed with respect to the axis of the disc and corumunicate with the interior of the housing 38. The pressurized gas within the housing passes through the apertures di) to rotate the disc at a comparatively high speed.

The remotely located end 22 (FIG. l) of the bundle 2d is provided with a suitable lens system 42 which. is cllective to detect and magnify the image from the bundle. Positioned in spaced relationship with the end 22 is a shielded screen lor observing the thus detected image.

A rotating reticle or mask 45 is interposed between the end 22 and the scrcn 33. The mask i5 is driven by a variable speed electric motor 46 having a hollow output shalt 57. The mask comprises a pair ol aperturcd chopper dts 5t? and 5l which are best shown in llGS. 2 and S. The disc Sti is provided with two diametrically opposed openings 53 and 5, while the disc 5l similarly includes two diametrically opposed openings 5S and S6 which overlap the openings 53 and 54. The discs 59 and 51 are coaxial with the motor shaft 47 and are arranged in spaced-apart relationship with each other.

The shaft 't7 is xcdly secured to the disc 50 by a bushing 6G attached to one face of the disc. Mounted on the opposite face of the disc Sil is a cup-shaped member A second cup-shaped member 63 carries the disc Si and is telescoped within the member 62 for axial sliding movement with respect thereto. The member 62 includes diametrically opposed diagonal slots 65 and 66 (FIG. 6) which respectively accommodate radially extending pins 67 and 63 on the member 63. A coil spring 70 is interposed between the members 62 and 63 and is provided with a nylon seat 7l on the member 62. The spring 7l) biases the member 63 and the attached dise 5i in an atrial direction away from the member 62 and thc attached disc 5t).

Slidably disposed within the hollow drive snalt is a control shaft 72. The shalt '72 is lteyed or otl erwise prevented from rotational motion but is arranged for limited movement in an axial direction. The shaft '72 includes an end cap 73 which engages a ball-bearing assembly 7S between the cap and the cup-shaped member 63. Upon axial movement of the shaft '72 to "-if as viewed in FIG. 5, against the biasing force by the coil spring 7G, the disc 51 is drawn to t disc Sti and rotates relative thereto a result of the d' onal slots and it'i and the cooperating pins 67 and tit. This rotational movement changes the position of the Openings 53 and 51% (FiG. 2) in the disc CG relative to the corresponding openings 55 and 56 in the disc :"il, lor purposes that will become more fully apparent herc inalter.

in operation, successive electrical current pulses are generated by the control circuit i5 at the desired irequency to produce a seriof elect arcs oetwe-.zn the electrode i3 and the worl: piece. These arcs form dropv lets of weld material which Contact the work piece at the frequency of the applied pulses to form the weld it). An optical image of the arcs and the droplets is continuotuy conducted to t. e lens system 42 along the image tra...)- mitting path defined by the liber optics bundle 20.

During the Aformation of the weld, the electric motor Lil-6 drives the mask at a constant speed which is proportional to the frequency at which the droplets of .vetd material Contact the worl; piece. rhe motor rotates its output shaft i7 which in 'turn drives the bushing G and the attached disc 5G. Driving power is transmitted from the disc :59 through the cupshaped member the pins 67 and rill and the cup-shaped member :E3 to rotate the disc Si in relationship with the disc 50.

he rotating dises .'St') and S1 are effective to periodically interrupt the image from the liber optics bundle 2O at the frequency of the welding pulses from the Control circuit 15. ln the illustrated embodiment, the Speed of the motor 45 is adjusted until it is equal to one-half the frequency at which the droplets of weld material contact the work piece, such that as cach droplet moves toward the worl; piece one of the Openings formed by the overlapping portions of the apertures S3, 51?-, 5S and 56 moves in front of the lens system 4Z. As each opening passes in front of the lens system, a momentary image of the weld appears on the screen d3. Because of the relationship between the frequency of these momentary images and the frequency at which the droplets of weld material are formed, a substantially stationary representation 73 (FIG. 3) of the droplets is detected by the screen.

The apparatus thus enables the direct visual observation of the droplets and the attendant arc to permit the making of almost instantaneous physical measurements. To ascertain the vertical dimension of the droplets or to determine the length of the are, lor example, the screen d3 is provided with a suitable graduated scale Si). The droplets and the are may be compared with linown standards and may be analyzed with respect to color, shape, size, intensity, drop velocity, puddle behavior, metal transfer rate, surface tension ellects and various other Observable phenomena.

During the formation of the weld, inert gas under pressure is continuously introduced into the housing 33 (FIG. 4) through the inlet 39. The gas passes through the apertures 4t) in transparent disc 35 to continuously rotate the disc at high speed. As the gas emerges from the forward face of the disc, it is radially deflected from the vicinity of the weld by the stationary cap 36. Splatter and other contaminants from the weld contact the rotating dise and are directed outwardly by centrifugal force away from the objective end 2l of the liber optics bundle 20` With this arrangement. the end 2l is maintained optically clean, and the formation of an extremely well-defined image on the screen i3 is insured,

To adjust the cirtective width of the openings in 'the mask 45 during the welding operation, the controlshaft 72 (FlG. 5) is moved in an axial direction relative tothel drive shaft 47 to vary the spacing between the discs SGT and El. As the disc 5l moves toward or away from the disc Si), the pins 67 and 68 slide in their corresponding slots 65 and 66 to produce a rotational force component which adjusts the relative angular positions between the discs. In cases in which the effective Width of the openings on the masi"- is to be reduced, for example, the shaft 72 is moved to the left, as viewed in FIG; 5, to urge the disc 5l toward the disc 5t) and simultaneously pivot the disc 5I in a clockwise direction (FIG. 2) relative to the` disc 5%. The effective Width of the openings may be varied in a rapid and straightforward manner as the mask rotatcs to vary the intensity and definition of the image on the screen 43. With this arrangement, the-optimum Width for the particular operating conditions may be readily established.

In several advantageous embodiments of the invention, the stationary representation of tbe Weld on the screen 43 is utilized to control the welding circuit 15. In these-ernbodiments, an electro-optical scanner S5 is employed to scan the screen 43 and produce one or more feedback signals corresponding to such parameters as are shape, size, color and intensity. To control the applied current and voltage. for example, feedback signals are produced which respectively correspond to the width and length of the arc as detected on the screen. The signals are differentiated and are transmitted to the circuit 15 through conductors 87 and 3S to permit the automatic adjustment of the welding operation in accordance with the detected characteristics of the arc. In a similar manner, the .color or other characteristics of the representation of the droplets may be scanned by the scanner SS to produce feedbacl: signals for controlling selected variables in the formation ofthe Weld.

Although the use of the rotating reticle or mask 45 has many important advantages, the inventionin its broadest aspects is not limited to a mask of this type. Thus, in some cases the image of the Weld may be modied through the use of stroboscopic lightingA effects, for example, to produce a substantially stationary representation ofthe image at the detector.

The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention, in the use of such terms and' expressions, of excluding any equivalents of the features shown and described, or portions thereof, it being recognized that various modifications are possible within the scope of the invention claimed.

What is claimed is:

I. In a welding system of the type in which a welding electrode is held in position adjacent a work piece to prO- j duce an electric arc therebetween,

means for applying periodically Ivarying electrical current to said welding electrodetogenerate an arc for forming a Weld,

light conducting means defining an image-transmitting path extending from adjacent said weld to a position remotely located with respect thereto, said light conducting means having an objective end in spaced juxtaposition with said weld,

optical detecting means disposed' at said remotely located position for receiving an image of said weld from said light conducting means, and

means between the arc and said detecting means for periodically interrupting said image at a predetermined frequency, to produce a series of momentary representations of said Weld at said detecting means.

ofweld material, said droplets contacting said work piece at the frequency of the applied pulses to form a'weld, light conducting means defining an image transmitting path extending frornadjacent said-droplets to a position remotely located with respect thereto, said light conducting means having an objective end in spaced `juxtaposition withvsaid droplets, optical detecting lmeans disposed at said remotely 1ocated position for receiving an image of said droplets from said light conducting means, and Y rneansbetween the arcs andsaid detecting means for modifying said image to produce a substantially stationary representation of-saiddroplets at said detect-i ing means.

3. In a weldingsystem of thev character set forth in claim 2, in which the modifying means comprisesreticle means interposed in the path of-said image for periodically interrupting. the same at a frequency proportional to the frequency at which said droplets contact said vvorltV piece.

4. In a welding systemof the character set forth in claim 3, sad'rectile means comprising:

a pair of apertured discs mounted for rotation about an axis parallel to the path of 'said image, and means for rotating said discs in xedrelationship with eachother.

5.' In a Welding system' of the character set forth in claim 4, means for adjusting the-angular position of one of said discs relative-to the other disc during the rotation thereof.

6. In a welding system of the'typein which a welding electrode-is held in position adjacent awork piece to produce'an electric arc therebetween,

control means for applying electrical current pulses to said welding electrode-'at a predetermined frequency to generate successive electric arcs for forming droplets of weld material, said droplets contacting said work piece at the frequency of the applied' pulses to forma weld,

lightI conducting means defining an image transmitting path extending from adjacent said droplets and said arcs to a'position-remotely located with respect thereto, said light conducting -means having an objective end' in spaced juxtaposition with said droplets and said arcs,

optical detectingr means disposed at said remotely located position for receiving an' image of said droplets and said arcs from said light conducting means, and

means between the arcs and said'detecting means for periodically interrupting said image at a frequency corresponding to the frequency at which said droplets contact said worlr piece, to produce a substantially stationary representation of said droplets and said arcs at said detecting means.

7.l 'In a Welding system ofthe character set forth in claim 6,

meansresponsive to the stationary representation of Said-arcsfor producinga feedbackv signal, and

means for transmitting said'feedbacl; signal'from said last-mentioned means tosaid controll means, said control means automatically adjusting-the pulses applied=to said weldingi electrode in accordance with the.' representation ofy said arcs.

8. In a Welding system of the'type inwhich a welding electrode is held in position adjacent a Work piece to produce an electric arc therebetween,

means for applying periodically varying electrical current to said welding electrode to generate an arc for forming a weld, said arc tending to produce splatter in the vicinity of said weld,

light conducting means defining an image transmitting path extending from adjacent said weld to a position remotely located with respect thereto, said light conducting means having an objective end in spaced juxtaposition with said weld,

means interposed between said Weld and the objective end of said light conducting means for preventing splatter from contacting said objective end,

optical detecting means disposed at said remotely located position. for receiving an image of said weld from said light conducting means, and

means between the arc and said detecting means for periodically interrupting said image at a predetermined frequency, to produce a series of momentary representations of said weld at said detecting means.

9. ln a welding system of the type in which a welding electrode is held in position adjacent a work piece to produce an electric arc therebetween,

means for applying electrical current pulses to said welding electrode at a predetermined frequency to generate successive electric arcs for forming droplets of weld material, said droplets contacting said work piece at the frequency of the applied pulses to form a weld, the application of said droplets to said work l piece tending to produce splatter in the vicinity of said weld,

light conducting means detining an image transmitting path extending from adjacent said weld to a position remotely located with respect thereto, said light conducting means having an objective end in spaced juxtaposition with said weld,

means interposed between said weld and the objective end of said light conducting means for preventing i splatter from contacting said objective end,

' optical detecting means disposed at said remotely located position for receiving an image of said droplets from said light conducting means, and

means between the ares and said detecting means for modifying said image to produce a substantially stationary representation of said droplets at said detecting means.

l0. ln a welding system of the type in which a Welding electrode is held in position adjacent a Work piece to produce an electric arc therebetween,

means for applying electrical current pulses to said welding electrode at a predetermined frequency to generate successive electric arcs for forming droplets of weld material, said droplets contacting said work piece at the frequency of the applied pulses to form a weld, the application of said droplets to said work piece tending to produce splatter in the vicinity of said weld,

light conducting means defining an image transmitting path extending from adjacent said weld to a position remotely located with respect thereto, said light conducting means having an objective end in spaced juxtaposition with said weld,

means including a continuously movable transparent member interposed between said weld and the objective end of said light conducting means for preventing splatter' from contacting said objective end,

optical detecting means disposed at said remotely lo cated position for receiving an image of said droplets from said light conducting means, and

means for periodically interrupting said image at a frcquency corresponding to the frequency at which said droplets contact. said work piece, to produce a substantially stationary representation of said droplets at said detecting means.

set forth in il. In a Welding system of thc characte` comprising a rotary disc supported adjacent the objective end of said light conducting means, and [luid pressure means for rotating said disc at a speed sullicient to direct splatter away from said objective end by centrifugal torce.

ft2. ln a welding system of the type in which a we ig electrode is held in position adjacent a wol-lc picco to produce an electric arc therebetween,

means for applying electrical current pulses to said welding electrode at a predetermined frequency to generate successive electric arcs for forming droplets of weld material, said droplets contacting said work piece at the frequency of the applied pulst to form a weld, the application of said droplets to said vuoi-l; piece tending to produce splatter in the vicinity of said Weld,

light conducting means defining an image transmitt'ng pathl extending from adjacent said weld to a position remotely located with respect thereto, said light cenducting means having an objective end in spaced juxtaposition with said weld,

means including a continuously rotatable transj'iarcnt member interposed between said weld and the objective end of said light conducting means for preventing splatter from contacting said objective end,

optical detecting means disposed at said remt ly located position for receiving 'ut image of said droplets from said light conducting rlans. and

rotary disc ymeans for perro cally interruptin said image at a frequency proportional to the frequency at which said droplets contact said .vor' piece., to produce a substantially stationary rept tation of said droplets at said detecting means, said disc means being supported at said remotely located position and having at least one adjustable aperture for modifying said image to produce said substantially stationary representation.

13. In a Welding system of the character set forth in claim 5.2, said disc means comprising a plurality of coaxial discs in spaced relationship with.

each other, and

means for rotating said discs at a constant speed.

In a welding system of the character set forth in. claim i3, in which cach of said discs includes a plurality of apertures therein, the apertures in one of said discs overlapping the apertures in the other disc, and adjustment means for varying the angular position of said on'c disc relative to the other disc, to modify the degree of overlap of said apertures.

l5. In a Welding system of the character set forth in claim ifi, said discs being rotated in l`t:\'ed relationship with each Othe', said adjustment means moving said one disc in an axial direction relative to the other disc during the rotation thereof and simultaneously varying said angu lar position. i

References Cited UNITED STATES PATENTS 3,449,544 6/1969 Needham.

-OSEPH V. TRUHE, Primary Examiner I. G. SMITH, Assistant Examiner 

